Disposable diaper



June 4, 1968 R. SABEE DISPOSABLE DIAPER 5 Sheetsf-Sheet l Filed March 29, 1965 A f: 2z

25 29 INVENTOR.

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June 4, 1968 R. sABEE 3,386,442

DISPOSABLE DIAPER Filed March 29, 1965 r 5 Sheets-Sheet 2 F l .Z0 INVENTOR.

A r roznsy June 4, 1968 R. sABEE DISPOSABLE DIAPER 5 Sheets-Sheet 5 Filed March 29, 1965 uuu E NTO Q ZE/NHQeQ-r .519556 BY [uli-L, LM WLM-Z4 ATTORNEYS United States Patent O 3,386,442 DISPSABLE DIAPER Reinhardt Sabee, 728 S. Summit St., Appleton, Wis. 54911 Filed Mar. 29, 1965, Ser. No. 443,298 Claims. (Cl. 12S-287) ABSTRACT OF THE DISCLOSURE A disposable diaper made from stock of generally rectangular over-all outline has its intermediate portion of materially less width than end portions of the diaper. A moisture absorbent filler is centered on an impermeable backing and is anchored by a moisture permeable facing sheet which is fastened to the moistureproof backing beyond the filler. Side strips connected with the backing sheet beyond the filler are also connected with the facing sheet over the filler, thereby sealing and strengthening the side margins.

This invention relates to improvements in disposable diapers which are form fitted, which concentrate the absorbent in the area of maximum usefulness, which are sealed against seepage of moisture from either the sides or from the ends, and which is reinforced along both side edges of the diaper.

The distribution and use of disposable diapers for infants or incontinent persons has reached a point at which full use of the absorbent and comparative cost of the various parts are major factors. Other important factors are the snugness of fitting and reduction of bulk where no absorbent is required, elimination of the possibility of seepage from the side edges or ends, and comfort to the user. Disposable diapers must be made by machine to rachieve a low enough labor cost allowing their use for large numbers of infants and others, and present machines lay the various layers of the diaper as superposed sheets of generally rectangular shape of approximately the same size. Such shape does not place all of the cellulose pulp absorbent filler where it is most effective and some of the filler is accordingly wasted and only provides undesirable bulk. The facing sheet is usually a non-woven fiber which is by far the most expensive of the materials so that diapers should be redesigned to make full use of a minimum of facing and to use the other and less expensive materials as much as possible.

A fully rectangular shape of a diaper with the usual full size layer of filler cannot be made snug fitting with a minimum of bulk and accordingly can be very uncomfortable and unsightly. However, whatever the shape, -a disposable diaper must be machine made and the filler volume should be reduced and relocated and the facing must be minimized to keep down cost. Hence the filler should be concentrated where it will al1 be used to the fullest extent while keeping the bulk of the diaper to that which will be comfortable in the crotch. The areas of diaper extending up over the abdomen and the buttocks other than adjacent the crotch may be wholly free from filler for snugger fitting as well as comfort in the sitting position of the user. The side edges and the ends of the diaper must be secure against seepage of liquids therefrom and the side margins should be reinforced to withstand concentration of stresses thereon. The backing may be folded over the filler to provide side margins free from filler or separate side strips may be laid over backing side margins and the filler edges, and such strips may be attached to the side edges of the facing. Thus the facing area is reduced to that required for transmission of moisture to the filler, the side edges are sealed and reinforcement is provided along the diaper side margins.

3,386,442 Patented June 4, 1968 The disposable diapers described herein are readily made on machines now in use with only such machine modifications vas are common in the paper converting industry. The diaper is of generally rectangular shape having a reduced width intermediate portion so that the end portions provide tabs of sufiicient length to form a waistband and the end portions are of sufficient length to be turned over for sealing the ends lagainst moisture seepage. The portions cut away to form the reduced width intermediate portion may be discarded or may be used to form ties for joining the end portions into a waistband. Where a maximum diaper size and maximum amount of absorbent filler is to be used, the edges of a middle area of the intermediate portion are cut out so that such area extends partially around the legs of the user.

The filler is omitted from the end portions of the diaper and is concentrated in a middle area of lapproximately one-half the length of the diaper. The filler is thickened centrally thereof and for at least approximately one-half its length and such thickening is in the middle diaper area to concentrate filler in the area of maximum use and to secure full use of all of the filler. If the filler is used as multiple layers, less adaptation of the present machine is required than if the ller is in one piece. But a one piece filler may be tapered or rounded as desired rather than having substantially square edges formed yby cutting layers to -given size. The moisture impervious backing extends sidewise of the filler to provide backing side margins of substantial width beyond the side edges of the filler. The side margins of the becking are folded over the side edges of the filler or separate strips are laid along lsuch side edges and are attached to the side margins of the backing. Thus both of the side edges of the diaper are sealed and its side margins are reinforced by the strips. The moisture permeable facing being the most expensive item and having the least mechanical strength is reduced in area and used only where its permeability is required.

In the drawings:

FIG. 1 is a perspective View looking at the inner or moisture-permeable surface of 'a disposable diaper according to the present invention.

FIG. 2 is a top plan view of the diaper with parts thereof broken away.

FIG. 3 is a longitudinal cross sectional view on line 3 3 of FIG. 2.

FIG. 4 is a transverse cross sectional view of the intermediate portion on line 4-4 of FIG. 2.

FIG. 5 is a fragmentary view similar to FIG. 1, to show folding over portions at the end to assure sealing the ends and provide a heavy waistband for pinning.

FIG. 6 is a view similar to FIG. 4, of a modified structure.

FIG. 7 is a plan view of a modified diaper further reduced in Width in an area in the intermediate portion to relieve lateral pressure on the legs.

FIG. 8 is a view similar to FIG. 7, of a `further modification.

FIG. 9 is a perspective view of a diaper with a modified form of filler therein.

FIG. lO is a cross-section taken on line 10-10 of FIG. 9.

FIG. 1l is a plan view of another modification of diaper in which the facing extends over and is attached to the backing side margins lto form side strips which are cut to provide ties for the waistband.

FIG. 12 is a cross-section taken on the line 12-12 of FIG. ll.

FIG. 13 is a perspective view showing the manner of folding of the ties shown in FIG. 11 to form the Waistband.

FIG. 14 is a plan view similar to FIG. 10 of a combination of some features of prior views plus an additional feature, and

FIG. 15 is a fragmentary view similar to FIG. 13, with the ties located to serve with folded ends as in FIG. 5.

Referring to numbered parts in the drawing, 2G designates end portions of my disposable diaper, which has its intermediate portion reduced in width below the width across the end portions and thus forms tabs 22 extending sidewise at each corner of the diaper, the tabs being of such size that the diaper may be folded across the ends (as in FIG. 5 at 21) and will still provide a waistband of sufficient width. The intermediate diaper portion 23 is considerably narrower than the diaper end portions and such intermediate portion has a portion herein named the middle area 24.

A backing sheet 27 of thin, flexible, opaque and waterproof material such as one of the thermoplastic synthetic resins, is of a width to form at least parts of a waistband for a person, and the overall length of the diaper extends from the preferred front and back waistband locations between the legs of the preson when the diaper is taut lengthwise, and forms the diaper outer surface. A first filler layer 28 of moisture absorbent material such as wood pulp free from hard or sharp particles and which has been lightly felted, is placed on the backing sheet 27. Layer 23 is of a width less than the width of the diaper intermediate portion 23 and may extend to the diaper end portions 20. Side margins 2.9 of the backing sheet are thus left uncovered for a purpose which will appear below. A second filler layer 39 is placed centrally on the first filler layer 28 and is both shorter and narrower than the first layer so that the ller does not interfere with the snugness of fit at the waistband and so that the filler acts as if tapered from a thickened center toward the edges of the first layer. Obviously, a single layer of filler may be used in a diaper otherwise made as described herein, in place of a filler with a thickened section.

A facing sheet 33 of liquid permeable material such as one of the soft, high wet strength, non-woven, cellulose materials known, is of a width to extend approximately to the side edges of the smaller filler layer 30 and for the full length of the diaper and is laid over the filler. The facing 33 may or may not be attached to the ller 28, 30 lbut the facing is attached to the backing 27 beyond the ends of the liller so that the filler will not shift endwise. Side strips 34 of the backing sheet are now folded over, or separate side strips are laid on, the side margins of the facing 33 and extend from end to end and along both side edges of the backing sheet. If the side strips 34 are separate pieces, they extend from the facing side margin to the side edge of the backing. Accordingly the side strips also provide a second layer of material over each of the end tabs 22. The facing 33 and side strips 34 provide the inner surface of the diaper.

In use, the end portions may be folded at 21 as shown in FIG. 5 and the joined backing 27 and side strips 34 seal the end and sides of the diaper. Hence regardless of the liquid conduction qualities of the filler and facing, there can be no seepage of liquid from the diaper at the ends thereof. If the side strips 34 are moistureimpermeable, the sealed layers of backing and side strips prevent seepage of liquid from anywhere along the side edges of the diaper. By matching diaper size to the size of the infant, it is possible to provide a diaper fitting snugly and with a minimum of bulk while providing adequate i'ller in and near the seat and crotch areas (middle area 24 of the diaper intermediate portion) where such filler is of maximum use.

In manufacture, a rectangular piece of backing 27, the fillters 28, and the facing 33 are laid in sequence. Side strips 34 are placed from the side edges of the backing over the facing sheet margins 37 (or the backing is folded over) and adhesively attached toward the edges of the facing sheet. Where the side strips are in contact with the backing sheet side margins 29 or ends 20, they may be joined by heat and pressure if lboth are thermoplastic, or by adhesive to seal the contacting backing-side strip surfaces together. Thereafter the diaper is cut to provide the end portion tabs 22 and the narrower intermediate portion 23. The stmcture provides seals against moisture seepage from the ends and the side edges of the diaper.

In FIG. 6, the narrower and shorter filler 3) is laid first and the large layer of filler 28 is then placed and extends over the side edges and ends of ller 30. Facing 33 is now placed and backing 27 is turned over to provide seal side margins 29 and is attached to facing side margins 37. Thus filler edges and ends are made smoother toward the facing side.

The modified diaper shown in FIG. 7 is similar to that described above, but the side edges of the intermediate portion 23 are now cut out as shown at 35. The side edges of ller layer 2S are now relatively close to the attached sideV edges Of backing and side strips so that the seal formed therebetween becomes quite narrow in cut outs 35 from the side edges and the sealed side margins and lie against the side edges of the filler. Hence it is unlikely that the combined edges of the backing and side strips will bear on the skin. Extensions 36 may be attached to the tabs 22 and be coated with a pressure sensitive adhesive for attachment to opposed tabs in forming the waistband. The extension may be the same synthetic used for backing and side strips and may be attached thereto y,in any suitable manner. In the structure shown in FIG. 8, a third iiller layer 31, of smaller size than second filler 30, is used. The filler layer 28 is also cut `out to conform to the -back and side strip cut outs 35 and thus maintain substantially the same Width of sealing of the side margins 29 throughout the entire intermediate portion, and reduce lateral pressure on the leg inner surfaces.

FIGS. 9 and 10 show a diaper similar to FIG. 1 with the filler made as a single layer having a thickened center longitudinal portion 42 tapering to thinner margins 43 along both the filler sides. Such one piece liller can be given other shapes so long as it provides greater thickness mid-portions as above described. In FIG. 9 the ller extends only for the length of the middle area 24 of the intermediate diaper portion, which leaves free from filler at least the greater portion of the diaper over the abdomen and buttocks.

In FIGS. 11, 12 and 13 the diaper is made generally rectangular with backing and facing coextensive and attached at the side margins and ends. But the composite side margins are now very wide and are attached to one another over their full Width 46 and two portions are cut along each side for use as ties. Thus side margins 46 have ties 47, 48 severally extending from the diaper end portions in the area which becomes the waistband. In manufacturing, the ties 47 and 43 are cut free to allow folding at right angle to a side of the diaper as shown at 49 in FIG. 13, and the fold 49 is attached to the end portion 20. The ties are of suicient length to be knotted or otherwise held together. If there is no attachment of the folds 4-9, the ties will still be effective but will not be aligned with the diaper end portions as shown. The facing and backing side margins are attached by a iiexible adhesive or binder which is preferably water impermeable and use enough adhesive to fill the nonwoven facing so that its side margins do not allow moisture spreading toward the side edges of the diaper. The same adhesive can also be used for facing portions over the edges `of the filler but need not fill the facing as the impermeable facing and backing side margins form adequate edge seals.

In the diaper of FIGS. 11-13 high wet strength papers, available at lower cost than the non-woven facing, are

satisfactory for some uses such as incontinent pads, in place of the facing. Such papers can be reinforced along the diaper edges with side strips of the paper or strips of backing and the like.

FIG. 14 shows ties 51, 52 remaining temporarily attached to the balance of the diaper and to one another by uncut bonds 53. Cut-outs 54 are made to allow insertion of a finger to pull the ends of the ties free from one another and from the balance of the side strips 46. Thus the diaper may be provided with ties remaining in substantially a single piece, for easier packing and handling and detached only upon use in contrast to the ties free from the diaper side margins and extending away from the end portions as shown in FIG. 13.

FIG. 15 shows ties 51, 52 terminating at a line approximating that defined by the diaper fold 21 of FIG. 5 turned toward the inner surface of the diaper. The tie fold 55 preferably lies on the diaper outer surface (backing 27) so that tension on the ties acts compressively on the inwardly folded portion 21 at the diaper end.

I claim:

1. A disposable diaper of generally rectangular outline but having an intermediate portion of less width than end portions of the diaper and comprising a moisture impermeable backing providing the diaper outer surface, a moisture absorbent filler on the backing and of less length than the backing and of less width than the backing intermediate portion to define backing side margins along the side edges of the filler, a moisture permeable facing on the filler having side margins extending longitudinally of the diaper between the side margins of the backing, said facing further having end portions projecting beyond the filler and in face contact with, and attached to, the backing beyond the ends of the filler, and moisture impermeable side strips connected with the backing along the side margins thereof beyond the filler and extending for substantially the full length of the filler from the backing side -margins to the facing side margins and attached thereto for sealing the side edges of the filler and strengthening the diaper side margins, the facing and side strips providing the diaper inner surface.

2. The diaper of claim 1 in which the filler occupies only the middle area of the diaper intermediate portion, the filler length being approximately one-half the length of the backing.

3. The diaper of claim 1 in which the filler nas a longitudinally extending thickened central portion and thinner side margins.

4. Thediaper `of claim 1 in which the yfiller is in multiple layers, one layer being of less width than and extending centrally along the length of an adjacent layer for providing a thickened central portion and thinner side margins of filler.

5. The diaper of claim 1 in which the filler is a multiple layer, one layer being approximately the length of and narrower than the diaper inter-mediate portion and another layer being narrower than the width of the said one layer and of the length only of the middle area of theintermediate portion and placed centrally of the said one layer.

6. The diaper of claim 1 in which the filler is integral with a thickened portion centrally and longitudinally thereof and with thinner side margins alongside the thickened portion.

-.7. The diaper of claim 1 in which the side margins of the middle area of the intermediate portion of the backing are reduced in width below the width of the remainder of the intermediate portion to reduce diaper edge pressure on the legs of the user.

8. The diaper of claim 1 in which the side margins of the middle larea of the intermediate portion of the backing and of the filler each have arcuate cut-outs of like width of approximately the length of the middle area to reduce diaper edge pressure on the legs of the user.

9. The diaper of claim 1 in which the side margin portions of the backing are folded about the filler and attached in moisture impermeable relation to the facing whereby to seal the edges of the `filler against leakage from the diaper and to strengthen the diaper side edges.

10. The diaper of claim 1 in which extension are attached to the side edges of the diaper end portions to extend laterally therefrom with an extension longitudinal edge substantially aligned with an end of the diaper.

11. A disposable diaper of generally rectangular outline but having an intermediate portion of less width than end portions of the diaper and comprising a moisture impermeable backing providing the diaper outer surface, a moisture absorbent filler on the backing and of less Width than the backing intermediate portion to define backing side margins along the side edges of the filler, a moisture permeable facing on the filler and attached to the backing beyond the ends of the filler, and side strips attached to and extending from the backing side edges to the facing side margins and attached thereto for sealing the side edges of the filler and strengthening the diaper side margins, the facing and side strips providing the diaper inner surface, the side strips being the side margins of the backing folded over the filler and remaining in one piece with the backing at the end portions of the diaper and being cut to a reduced width intermediate portion and being attached from the backing side edges across the width of the backing side margins along the entire side edges of the intermediate portion of the diaper.

12. A disposable diaper of generally rectangular outline but having an intermediate portion of less width than end portions of the diaper and comprising a moisture impermeable backing providing the diaper outer surface, a moisture absorbent filler on the backing and of less width than the backing intermediate portion to define backing side margins along the side edges of the filler, a moisture permeable facing on the filler and attached to the backing beyond the ends of the filler, and side strips attached to and extending from the backing side edges to the facing side margins and attached thereto for sealing the side edges of the filler and strengthening the diaper side margins, the facing and side strips providing the diaper inner surface, the side strips being separate from and being attached along the entire length of both the backing and the facing side margins and enclosing the side edges of the filler.

13. A disposable diaper of generally rectangular outline but having an irgtermediate portion of less width than end portions of the diaper and comprising a moisture impermeable backing providing the diaper outer surface, a moisture absorbent filler on the backing and of less width than the backing intermediate portion to define backing side lmargins along the side edges of the filer, a moisture permeable facing on the filler and attached to the backing beyond the ends of the filler, and side strips attached to and extending from the backing side edges to the facing side margins and attached thereto for sealing the side edges of the filler and strengthening the diaper side margins, the facing and side strips providing the diaper inner surface, tabs formed by the side end portions extending laterally beyond the intermediate portion side edges and being adhesively coated for attachment to one another for forming a waistband from the end portions and tabs of the diaper.

14. A disposable diaper of generaly rectangular outline but having an intermediate portion of less width than end portions of the diaper and comprising a moisture impermeable backing providing the diaper outer surface, a moisture absorbent filler on the backing and of less width than the backing intermediate'portion to define backing side margins along the side edges of the filler, a moisture permeable facing on the filler and attached to the backing beyond the ends of the ller, and side strips attached to and extending from VVthe backing side edges to the facing side margins and attached thereto for sealing the side edges of the filler and strengthening the diaper side margins, the facing and side strips providing the diaper inner surface, ties being cut longitudinally along each side edge of the diaper intermediate portion beginning from adjacent the diaper ends and terminating substantially midway of the length of the diaper, the ties being free from and defining the side margins of the intermediate portion of the diaper.

l5. The diaper of claim 14 in which ties cut from the sides of the diaper are folded to a right angle with and extend laterally from the diaper end portions and the fold surfaces are attached to one another and to a surface of the diaper end portion adjacent to a tie fold surface for transmitting tension on the ties transversely of the diaper end portions.

References Cited UNITED STATES PATENTS Crane 1218-287 Lonberg-Holm 128--287 Osborn 12S- 287 Sanford 128--287 Duncan et al. 128--287 Hrubecky 12S-287 Sabee 12S- 287 Joa 128-290 RICHARD A. GAUDET, Primary Examiner.

a CHARLES F. ROSENBAUM, Examiner. 

